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Monmouthshire Waggon

This is where we don't want anything but evidence of your finest wood butchering in all its glorious, and photograph laden glory. Bring your finished products or WIP's, we love them all, so long as there's pictures, and plenty of 'em!

Re: Monmouthshire Waggon

Postby Dalboy » 09 Apr 2019, 22:16

I have neglected this project for too long so today I cleared the workshop benches and other surfaces. The parts for the waggon are now on the bench so that I can get and complete it.

More to follow soon
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Re: Monmouthshire Waggon

Postby Mike G » 10 Apr 2019, 08:01

Coincidentally, I am following a full sized wagon build on Youtube at the moment, here. It was brilliant until this week when he went on a bit of a rant.
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Re: Monmouthshire Waggon

Postby Dalboy » 10 Apr 2019, 09:39

Mike G wrote:Coincidentally, I am following a full sized wagon build on Youtube at the moment, here. It was brilliant until this week when he went on a bit of a rant.


I have watched them as well, some useful information. I find that there are some channels where they ramble on a bit.
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Re: Monmouthshire Waggon

Postby Dalboy » 10 Apr 2019, 20:31

Made a start by cutting out lap joints on the swivel assembly top bar as well as the matching ones on the underside of the main waggon bed.

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Glued in place and clamps removed

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A quick photo of through mortice and tenon joints to give an idea of what scale I am making joints at

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Re: Monmouthshire Waggon

Postby Malc2098 » 10 Apr 2019, 21:10

Nice.
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Re: Monmouthshire Waggon

Postby Dalboy » 11 Apr 2019, 17:34

I have had to work from a book on this as the plans that I started with went into hiding as I put them somewhere safe after most of yesterday and an hour this morning of searching they were found. The book scale is different from the plans

Back on track but still not a great deal was done as it seemed to take ages to mark out and cut the first two mortice and tenons. If these are not at the correct angle it will put all the others out to make things worse the plans are slightly off as the two shafts are identical but when rested on the plans it shows the drawing has one longer than the other this is not the only mistake. Double checking everything, however, I do appreciate that when these waggons were originally built they made them without plans.


Tenon cut on the shaft cross piece, this is quite a long tenon as it has to pass through the shafts into the shaft braces

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next was to cut the mortice for the tenon I tried to drill three holes in line but due to the size of the bit it kept trying to wonder off so I went with just two holes and then cut them out using a marking knife as even the smallest chisel I had was too thick to pass through. it was then cleaned up with needle files to the size of the tenon.


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Dry fit of one side


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As can be seen, both are now cut ready to mark out the shaft shutter this on the plans showed it protruding out one side more than the other. next job cut the tenon on the end of the shafts and mortices into the shaft shutter.

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Re: Monmouthshire Waggon

Postby Malc2098 » 11 Apr 2019, 17:41

Still nice.
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Re: Monmouthshire Waggon

Postby Dalboy » 11 Apr 2019, 18:12

Malc2098 wrote:Still nice.


Thank you, Malcolm
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Re: Monmouthshire Waggon

Postby DaveL » 11 Apr 2019, 19:51

It's good to see you working on this again.
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Re: Monmouthshire Waggon

Postby Dalboy » 11 Apr 2019, 22:23

DaveL wrote:It's good to see you working on this again.


The problem is that I have about 5 or 6 projects on the go at the same time. And even then I will break off once a month to turn something for the club competition.
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Re: Monmouthshire Waggon

Postby Dalboy » 12 Apr 2019, 19:18

A slow day today first off I did another check of measurements and found that one of the pieces did not match the thickness of the shafts when I checked with the plans they showed them the same but the cutting list and diagram of the piece in question match what I cut it to.
Have now cut it as can be seen.

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Marked out and then the tenons on the end of the shafts cut as well as drill the holes for the mortices. One tenon looks longer than the other and it is but will be cut to correct length later once it is assembled.

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I also dug out some of the pieces that I had prepared at the very beginning as I am sure I will need them later.

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Re: Monmouthshire Waggon

Postby Dalboy » 13 Apr 2019, 19:16

The grandchildren descended today but I have managed to get a little done on the waggon even if it is only a couple of mortice and tenons as well as some marking out of the shaft braces.

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Re: Monmouthshire Waggon

Postby Dalboy » 14 Apr 2019, 21:46

Again very little done was hoping to have completed all the mortice and tenons on the shaft assembly but it was not to be but I did manage a couple.


Marked out and mortice cut

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A dry fit and clamped to hold pieces in place ready for two more mortices to be cut need another clamp before final marking out

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These are the tools I have been using to do all the work on this piece so the bench is staying quite tidy the only other thing I used is my trusty bench drill

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Re: Monmouthshire Waggon

Postby Dalboy » 15 Apr 2019, 18:59

May not look like a lot has been done but what has is time-consuming, cut the last of the mortice and tenons on the shaft assembly. Then assembled and did some fettling to make sure they all fit just right and close any gaps that needed it.

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Took it all apart yet again and gave it a final clean up to get rid of any pencil marks which would be hard once assembled for the last time.

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The last assembly now on the way with parts being glued up the bar nearest to us is only there to keep it aligned while the first glued items dry.

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I will glue some more up tomorrow and while that is drying I will get some more wood prepared I have managed to find some more Oak that is a match to what I have already used as I don't want too much of a mismatch.
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Re: Monmouthshire Waggon

Postby Dalboy » 16 Apr 2019, 21:26

I have glued up some more on the shaft assembly.


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Anyway while that is sitting and drying I needed some more 1/8" thick pieces for the waggon sides and bed.

Started with this lump of Oak 3 1/2" X 2" X15" long. I would have liked to make the pieces the 3 1/2" but the grain was not looking right so went with slices off of the 2" side to give the effect I wanted.
I ended up probably with more than I needed I will mark them up and put them in the wood drawer for future models/toys

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Marked up ready when needed

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Cut down to the widest width I needed and also to length. I did juggle them around so that the grain was not lining up as I wanted it to be obvious that they are all separate planks. The edges have a small chamfer on them also to help show the joints. Each set of 8 planks were to wide for where they fit so some planks planed narrower so no two are the same.

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A temporary guide fitted in place to allow the two end planks to be glued in place the guide then removed until they are dry this will give me somewhere to replace the guide for the next two and so on

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It is surprising how long it takes to do what appears to be a simple job.
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Re: Monmouthshire Waggon

Postby Dalboy » 17 Apr 2019, 22:11

Had to bring the big clamps out for the shaft assembly two sash clamps. Still another piece to fit to this before starting on the metalwork

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Started clamping the bed boards and throughout the day got them all on

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While the shaft assembly and the bed boards are drying I thought I would start the sides and headboard, getting parts to match up seemed to take most of the time but pleased with the fit. All of the bed boards side panels and headboard are from Oak the plans say to use 1/8" ply which will not match the rest

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Re: Monmouthshire Waggon

Postby Malc2098 » 17 Apr 2019, 22:12

looking nice.
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Re: Monmouthshire Waggon

Postby Phil » 18 Apr 2019, 18:09

That is extremely nice Derek! 8-)

Very small finicky work, lots of patience and concentration.
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Re: Monmouthshire Waggon

Postby Dalboy » 21 Apr 2019, 21:40

Thank you Malcolm and Phil. Nothing done over the last couple of days veg patch needed digging and trying to repair my lathe
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Re: Monmouthshire Waggon

Postby RogerS » 21 Apr 2019, 22:02

Bloody Hell, mate. That last photo showing the bench stop brings the scale of this into perspective. Those joints are tiny
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Re: Monmouthshire Waggon

Postby Dalboy » 22 Apr 2019, 00:00

RogerS wrote:Bloody Hell, mate. That last photo showing the bench stop brings the scale of this into perspective. Those joints are tiny


If you look near the top of this page it shows a through mortice and tenon joint with a ruler :lol: :lol: :lol:
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Re: Monmouthshire Waggon

Postby DaveL » 22 Apr 2019, 00:19

So what's happened to your lathe? Hopefully it's not too serious.
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Re: Monmouthshire Waggon

Postby Dalboy » 22 Apr 2019, 14:02

DaveL wrote:So what's happened to your lathe? Hopefully it's not too serious.


Motor packed up. Have a new motor but the old one had a 5/8" shaft and the new has a 16mm not much between them but enough for the pulley not to fit. Will be onto Record tomorrow morning
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Re: Monmouthshire Waggon

Postby fiveeyes » 23 Apr 2019, 18:13

You sir, have the patience of Job. :text-coolphotos:
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